Feature

Technical Developments in 2020

1979
Shioda Works51

May 2021

COLUMN
Cover image:

Shioda Works
1979

The 1970s was a time when office workers started using computers,
word processors, and other computer devices in common, and the officeautomation market was on the rise as a promising market. These devices
required many fans to cool them.
To meet this demand, we newly established a mass-production base ofsmall-sized motors in Ueda City, Nagano Prefecture in April 1979.
Shioda Works was opened as a factory that specialized in producing the
San Ace cooling fans, and its production capacity had steadily grown overtime. In 1982, it underwent a major expansion to increase its capacity.
In 1990, however, to realize an even greater production capacity in the
future, we established a new production base of the San Ace products, thatis, the Fujiyama Works.
Since then, the Shioda Works has made contributions continuously by
producing servo amplifiers and PV inverters, then currently stepping
motors.

51
May 2021

SANYO DENKI TECHNICAL REPORT
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Groundbreaking Ideas and Development Enhancementfor 20% Faster Development Operating Officer Koichi Uchibori

1

Features: Technical Developments in 20203

■ Cooling Systems Division

Highlights of 2020 and New Products Introduction

Masato Murata .......................... 3

40 × 40 × 56 mm San Ace 40 9CRJ TypeCounter Rotating Fan Masaki Kodama and Others ........................................................................... 6
80 × 80 × 38 mm San Ace 80 9HVB TypeHigh Static Pressure Fan Masato Kakeyama and Others ............................................................... 10■ Power Systems Division

Highlights of 2020 and New Products Introduction

Satoru Shimizu ......................... 14

Development of the SANUPS C23A Voltage Dip Compensatorwith Compliance with European Standards Hiroaki Miyoshi and Others ........................... 18
Development of the SANUPS E11B Hybrid UPS

Akihiro Tsukada and Others .................. 22■ Servo Systems Division

Highlights of 2020 and New Products Introduction

Yasutaka Narusawa .................. 27

Development of the SANMOTION R 400 VAC Input
Multi-axis Servo Systems (37 kW, 300/600 A) Masaaki Mizusawa and Others ................... 30
Internal Recognition: Invention Excellence Award

37

Internal Recognition: Manufacturing Excellence Award

37

Major Patents

38

Technical Papers Published Outside the Company
in General Technical Journals

40

Technical Papers Published Outside the Company

40

Groundbreaking Ideas
and Development Enhancementfor 20% Faster Development
Koichi Uchibori Operating Ofﬁcer

The year 2020 will be remembered as the year in which COVID-19 swept
across the world, leaving no one unaffected by it.
In the Philippines, our group company, SANYO DENKI PHILIPPINES,
INC. (hereinafter, “SDP”) was ordered by the government to suspend its
operations for about two months to prevent the spread of the infection. I wasin the Philippines at the time and stayed there until production was restored. It
was a challenging time that required us to perform measures through trial anderror to satisfy the government’s COVID-19 regulations and conditions.
Furthermore, our cooling fans and stepping motors were being used in
medical equipment for treating patients with COVID-19. These equipment
included ventilators and devices for pulmonary function testing, diagnostic
blood testing, and therapeutic research. Since the timely supply of theseproducts could help save lives, our first priority was to restart production oncebusiness operations resumed.
T his experience made me further reali ze why high- quality, highperformance, and high-reliability products, such as ours, are being widely usedin the field for medical equipment. Our mission is to continue to contribute tosociety by supplying the world with the various types of products it needs.
Our 8th Mid-term Management Plan started in April 2016 and ended in
March 2021. It aimed to “continue to develop world-leading products in termsof quality, performance, and reliability.” Over the past five years, our Cooling
Systems Division, Power Systems Division, and Servo Systems Division
released a total of 70 new products.
The Cooling Systems Division released 31 new products.
In particular, the division developed high airflow and high static pressurefans that achieve the industry’s top* cooling performance. These fans weredeveloped to enhance cooling capability in high-performance equipmentwith high component integration, such as servers, storage devices, and ICT
equipment.
In addition to developing products for cooling applications, the divisionused customer feedback to develop a PWM controller that can regulate therotational speed of fans externally and the industry’s first* airflow tester thatcan easily measure system impedance and operating airflow when selecting

1

SANYO DENKI Technical Report No.51 May 2021

cooling fans. In the future, the division plans to increase the number of
products optimized for airflow.
The Power Systems Division released 22 new products.
In addition to developing compact and maintenance-free UPSs thatuse lithium-ion batteries to achieve long-term backup in various operating
temperature ranges, the division has been developing power conditioners for
power generation systems that use renewable energies such as photovoltaic
power, wind power, and small- and medium-scale hydroelectric power sources.
The Servo Systems Division released 17 new products.
The division has been increasing the number of IoT-ready products. These
include servo amplifiers that come with monitoring features for predicting
equipment failure based on the operating status of amplifiers and motors, aswell as products that can use smartphones and tablets to wirelessly monitor
the status of robot and conveyor controllers.
Moving forward, we plan to continue developing products that contribute tocustomer productivity.
Our 9th Mid-term Management Plan started in April 2021 based on theconcept of “breaking new ground.” One of the key policies of the plan is to“develop products that make new dreams come true.”We aim to develop groundbreaking products and create new value by
combining our cultivated technologies with new technologies, while pursuingincreased development speeds of up to 20%.
To help achieve this goal, we opened a new building at our Technology
Center in May 2021.
As a result, the center has laboratory space that is nearly twice the sizeof the previous one and provides a work environment that greatly facilitates
design and development. By combining this center with our SDP Technology
Center, which we opened in March 2019, we plan to accelerate global productdevelopment by breaking new ground and enhancing our development
capabilities so that we can strengthen our brand name throughout the world.
* Based on our own research as of May 15, 2021.

SANYO DENKI Technical Report No.51 May 2021

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Feature: Technical Developments in 2020

Cooling Systems Division
Masato Murata

Remote work has been introduced
at many companies as a measure
to prevent the spread of COVID-19.
As a result, the Internet and othertypes of ICT systems are playing avery important role in new lifestyles,
business ac ti v ities, and so c i alactivities.
Elements of ICT equipment suchas servers, storage devices, androuters have been constantly
improving in terms of speed, capacity,and performance, and they havebeen mounted in equipment withhigher density. At the same time, thehigh density mounting of these typesof equipment has increased heatbuildup, which, in turn, has increased
demand for fans with higher airflow
and static pressure.
Also, equipment used outdoors
such as base stations, PV inverters,
and digital signage has increased
performance, there has also been

■ High Static Pressure Fan

DC Fan• 40 × 40 × 28 mm San Ace 40 9HVA type

40 × 40 × 28 mm fans are used inefficient. This means that fans also

1U servers and other ICT equipment.

need to operate with low power. To

This equipment these days has higher

meet such demands, we developed andperformance than before, requiring

launched the San Ace 40 9HVA typemore effective cooling. In addition,

fan. It offers the industry’s highest (1)today’s devices are required to be eco-static pressure.

(1) Based on our own research as of May 28, 2020, conducted among equally-sized axial
DC fans on the market.

3

increased demand for water-resistantfans with higher cooling performanceto accommodate the advanced
features and performance of outdoor
base stations, PV inverters, anddigital signage.
To meet such market demands, wedeveloped and launched fans withindustry-leading performance andreliability.
B el ow is an over v iew of the
products we developed in 2020.

SANYO DENKI Technical Report No.51 May 2021

• 80 × 80 × 38 mm San Ace 80 9HVB type

80 × 80 × 38 mm fans are used in

In response to such market demands,

high-density equipment such as 2U

we developed and launched the San

servers, storage devices, and routers.

Ace 80 9HVB type fan that features theThis equipment these days has higher

industry’s highest(2) airflow and static

performance than before, requiringpressure.

more effective cooling.
(2) Based on our own research as of September 29, 2020, conducted among equally-sized
axial DC fans on the market.

• 92 × 92 × 25 mm San Ace 92 9HV type

9 2 × 9 2 × 25 mm fans are being

cooling performance. In response to

used widely in IC T and industrial

such market demands, we developed andequipment. Advancements in equipment

launched the San Ace 92 9HV type fan

performance and miniaturization havethat has the industry’s highest(3) airflow

increased the heat generation insideand static pressure.

equipment, requiring fans with higher(3) Based on our own research as of March 10, 2020, conducted among equally-sized axial
DC fans on the market.

■ Counter Rotating Fan

DC Fan• 40 × 40 × 56 mm San Ace 40 9CRJ type

40 × 40 × 56 mm fans are being used

To meet such market demands, wein 1U servers and switching power

developed and launched the San Ace 40

supplies. This equipment these days has

9CRJ type fan that has the industry’s

higher performance, calling for fanshighest(4) static pressure with low powerwith higher cooling performance andconsumption.

lower operating power consumption.
(4) Based on our own research as of August 18, 2020, conducted among equally-sized axial
DC fans on the market.

SANYO DENKI Technical Report No.51 May 2021

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Feature: Technical Developments in 2020

■ Splash Proof Fan

DC Fan• 60 × 60 × 25 mm San Ace 60W 9WPA type
• 80 × 80 × 25 mm San Ace 80W 9WPA type
• 92 × 92 × 25 mm San Ace 92W 9WPA type

Our Splash Proof Fans have beenused in outdoor equipment such as

sizes, and generates more heat, requiring

San Ace 60W, San Ace 80W, and San

more effective cooling than before.

Ace 9 2W 9W PA types. These fansbase stations, PV inverters, and digitalI n response to th is dema nd, weoffer the industry’s highest(5) coolingsignage. However, this equipment thesedeveloped and released the following

performance (high airflow and staticdays has higher performance and smaller

high-performance Splash Proof Fans:pressure) and IP68(6) protection.

(5) Based on our own research as of April 14, 2020, conducted among equally-sized waterproof axial DC fans on the market.
(6) IP68 ingress protection
The degree of protection (IP code) is defined by IEC (International Electrotechnical Commission) 60529 “Degrees of Protection
Provided by Enclosures (IP Code).” (IEC 60529:2001)■ Centrifugal ACDC Fan and Splash Proof Centrifugal ACDC Fan• ø190 × 88 mm San Ace 190AD 9ADTU type Centrifugal ACDC Fan• ø190 × 88 mm San Ace 190AD 9ADW1TU type Splash Proof Centrifugal ACDC Fan

ø175 to ø250 mm AC centrifugal fansand higher water resistance. In response

are being widely used in air conditioning

to such market demands, we developed

systems, large inverters, and outdoor ICT

and launched the San Ace 19 0A D

equipment.

9ADTU type Centrifugal ACDC Fans

Advancement of this equipment has

and 9A DW1T U type Splash Proof

required cooling fans with higher coolingCentrifugal ACDC Fans. These fans offer

performance, lower power consumption,

the industry’s highest(7) static pressure.

(7) Based on our own research as of December 8, 2020, conducted among equally-sizedwaterproof or non-waterproof industrial centrifugal fans on the market.

AuthorMasato Murata
Design Dept., Cooling Systems Div.
Works on the development and designof cooling fans.

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SANYO DENKI Technical Report No.51 May 2021

AC FanNew Product Introduction

40 × 40 × 56 mm San Ace 40 9CRJ TypeCounter Rotating Fan
Masaki Kodama

Toshiki Kobayashi

Ryo Shimizu

Hiromitsu Kuribayashi

Toshiya Nishizawa

1. Introduction
In the 1U server, ICT equipment, and power supply
market, there has been increasing demand for highperformance and compact fans for cooling today’s advanced
and high-density equipment. As a cooling solution for thismarket, we have developed and offered 40 × 40 × 56 mm
Counter Rotating Fans since quite a while. However,today’s high-density equipment has required even higher
cooling performance. Moreover, in recent years, manycustomers have also put an importance on eco efficiency

Fig. 1 40 × 40 × 56 mm San Ace 40 9CRJ typefor environmental conservation, which has become anothertarget in our product development.

(1) High static pressure

To meet these requirements, we developed and releasedt he S a n Ac e 4 0 9 C R J t y p e C ou nter Rot at i ng Fa n(2) High airflow(3) Low power consumption(hereinafter, “new model”). It comes with a newly designed
impeller and frame and features high performance and low
power consumption.

The new model achieves improved performance with thesame size as the current model.

This article will introduce the features and performanceof the new model.

3. Product Outline

2. Product Features

3.1 Dimensions
Figure 2 shows the dimensions of the new model. The

Figure 1 shows the appearance of the new model.

external dimensions and mounting hole dimensions are

The features of the new model are:unchanged and compatible with the current model.

Inlet side

+30
320 0

4-ø3.5±0.3
Mounting
hole

Outlet side
56±0.5（10）（ 5）40±0.332±0.3（5）32±0.340±0.3

（10）

+30
320 0
Lead wire
AWG 26
UL 10368

Rotating direction

Airflow direction

4-ø3.5±0.3
Mounting
hole

Rotating direction

Fig. 2 Dimensions of the new model (unit: mm)

SANYO DENKI Technical Report No.51 May 2021

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3.2 Specifications
3.2.1 General specifications
Table 1 shows the general specifications for the new model.
The rated speed is 36,200 min -1 on the inlet side and32,000 min-1 on the outlet side.

Table 1 General specifications for the new model
Operating
Rated
PWM duty Rated Rated
voltagevoltagecycle* current input
range
[V]
[%]
[A]
[W]
[V]

Model no.

9CRJ0412P5J001

10.8
to
12.6

12

100

3.1

20

1.2

Sound Operating
Expectedpressure temperature
life
level
range
[h]
3
[m /min] [CFM] [Pa] [inchH2O] [dB(A)][˚C]
30,00037.2 36,200/32,000 1.06
37.4 2,400 9.64
72
at 60˚C-20 to +70(53,000
1.2 4,500/4,000
0.11
3.9
40
0.16
28
at 40˚C)
Rated speed[min-1]Max. airflow

Max. staticpressure* The PWM input frequency is 25 kHz; the fan speed at 0% PWM duty cycle is 0 min -1.
Note: The expected life at an ambient temperature of 40˚C is for reference purposes only.

4. Key Points of Development

3.2.2 Airflow vs. static pressure
characteristics
F i g u r e 3 s h ow s t h e a i r f l ow v s . s t a t i c p r e s s u r e

The new model offers significantly improved airflow andcharacteristics for the new model. Shown are examples atstatic pressure. To achieve higher performance, we newly

PWM duty cycles 100% and 20% at a rated voltage of 12 V.

designed the impeller and frame.
In the following sections, we’ll explain the key points of

3.2.3 PWM control function

the development and the differences between the new model

The new model has a PWM control function that enables

and the San Ace 40 9CRH type fan (hereinafter, “current

external control of fan speed.

model”).

3.3 Expected life

4.1 Impeller and frame design

The new model has an expected life of 30,000 hours at

A Counter Rotating Fan has an inlet fan and an outlet

60°C (survival rate of 90%, run continuously at rated voltage

fan, and the combination of their shapes, blade angles,

and normal humidity in free air).

and rotational speeds significantly varies the product’s
airflow vs. static pressure characteristics. To achieve the[inch H2O]

[Pa]

10

2500

12 VDC

optimize the blade angle and the shape of the impeller and100% PWM
duty cycle
8target performance, we used 3D printing and simulations toframe
Figure 4 shows a comparison of the impeller shape for the2000

Static pressure

new and current models.
6

We increased the blade surface area by 10% on the inlet

1500

side and 3% on the outlet side compared to the current
model, thereby achieving high airflow and high static

4pressure. Although power consumption usually increases

1000

in proportion to the increase in blade surface area, we were20

actually able to reduce power consumption by optimizing

20% PWM
duty cycle

500

0

0.2
0

0.4
10

the blade shape.
0.6
20

0.8

1.0

30

1.2 [m3/min]
40 [CFM]

Airflow

Fig. 3 Airflow vs. static pressure characteristicsof the new model

7

SANYO DENKI Technical Report No.51 May 2021

図版の文字

123

英語版用

Condens

英語版用

Times Ten

40 × 40 × 56 mm San Ace 40 9CRJ Type Counter Rotating Fan

2800

Voltage: 12 V
PWM duty cycle: 100%

2600

New model 9CRJ0412P5J001
Current model 9CRH0412P5J001

10% higher operating airflow

2400
2200

1.4 times

2000

Inlet side

Inlet side

Static pressure [Pa]

1800
1600
1400

Estimatedsystem impedance

1200
1000
800
600
400

Outlet side

Outlet side

New model

Current modelFig. 4 Comparison of the impeller shapes
for the new and current models

200
0
0.00

0.20

0.40

0.60

0.80

1.00

Airflow [m3/min]

1.20

1.14 times

Fig. 5 Airflow vs. static pressure characteristics(Compared with the current model)

5. Comparison with Current Model

airflow and maximum static pressure are, respectively, 1.14

2200

times and 1.4 times that of the current model. The figure

2000

shows that the operating airflow of the new model is 10%

5.2 Power consumption comparison
with the current model at equivalent
performance
Figure 6 compares the power consumption between the
new model and current model at the same maximum airflow.

25
20
15
10

1200

5

1000

0

800
600

control and cooling performance is equivalent to that of200

range.

New model 9CRJ0412P5J001(at equal maximum airflow)
Current model 9CRH0412P5J001

1400

400

power than the current model in the estimated operating

30

1600

When the speed of the new model is lowered by PWM
the current model, the new model consumes up to 20% less

20% reduction max.

1800
Static pressure [Pa]figure.

35

2400

characteristics of the new and current models. Maximum

system impedance (ventilation resistance) shown in the40

Voltage: 12 V

2600

Figu re 5 compares the ai r f low vs. static pressu rehigher than that of the current model at the estimatedEstimated operating range

Power consumption [W]2800

5.1 Comparison of airflow vs. staticpressure characteristics

0
0.00

0.20

0.40

0.60

0.80

1.00

Airflow [m3/min]Fig. 6 Power consumption comparison
with the current model

SANYO DENKI Technical Report No.51 May 2021

8

40 × 40 × 56 mm San Ace 40 9CRJ Type Counter Rotating Fan

6. Conclusion
This article has introduced the features and performanceof the 40 × 40 × 56 mm San Ace 40 9CRJ type Counter
Rotating Fan with high performance and low power
consumption.
T he new mo del out per for m s ou r cu r rent mo del .
Furthermore, the new model consumes much less power
than the current model when maximum airflow is equivalent
to that of the current model.
We bel ieve the new model’s featu res w i l l g reatly
contribute to the cooling of high heat-generating, highdensity equipment that are expected to become increasingly
common in the future.
We will continue developing products that meet market
needs to contribute to creating new value for our customers.

Author

Masaki Kodama
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Toshiki Kobayashi
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Toshiya Nishizawa
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Ryo Shimizu
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Hiromitsu Kuribayashi
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

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SANYO DENKI Technical Report No.51 May 2021

New Product Introduction

80 × 80 × 38 mm San Ace 80 9HVB TypeHigh Static Pressure Fan
Masato Kakeyama

Yo Muramatsu

Yuto Horiuchi

Honami Osawa

Naoya Inada

1. Introduction
In recent years, ICT equipment, such as servers, storage
devices, and routers, have improved in terms of performanceand functionality. However, these enhancements haverequired denser internal component mounting, leading
to increased heat generation. As a result, higher coolingp er for m a nc e i s b ei ng re qu i re d for t he s e t y p e s ofapplications. We released the 80 × 80 × 38 mm San Ace 80
9HVA high static pressure fan (hereinafter, “current

Fig. 1 80 × 80 × 38 mm San Ace 80 9HVB typemodel”), but there was increasing demand for a high staticpressure fan capable of cooling equipment under higher
density and higher heat generating environments.

(1) High static pressure

To meet this demand, we developed and released the San(2) High airflow

Ace 80 9HVB High Static Pressure Fan (hereinafter, “new(3) Size suitable for 2U units

model”). It features a newly designed impeller, frame, andcircuit.

The new model improves performance, while maintaining

This article will introduce the features and performancethe same size of the current model.

of the new model.

3. Product Outline

2. Product Features

3.1 Dimensions
Figure 2 shows the dimensions of the new model. The

Figure 1 shows the appearance of the new model.

external dimensions and mounting hole dimensions are

The features of the new model are:unchanged and compatible with the current model.
4-ø4.5±0.3
Mounting hole80±0.571.5±0.3

38±0.5（4）（ 4）71.5±0.3
80±0.5

+50
300 0
（10）

Rotating direction

Airflow direction

Fig. 2 Dimensions of the new model (unit: mm)

SANYO DENKI Technical Report No.51 May 2021

10

3.2 Specifications
3.2.1 General specifications
Table 1 shows the general specifications for the newmodel. It is available with a rated voltage of 12 VDC and has
a rated speed of 18,300 min-1 (G speed).

Table 1 General specifications for the new model
Operating
Rated
PWM duty Rated Rated Rated
Max. airflow
voltagevoltagecycle* current input speed
range
-1
[V]
[%]
[A]
[W] [min ] [m 3/min] [CFM][V]Model no.

9HVB0812P1G001

100

10.8
to
12.6

12

20

4.8

58

18,300

4.0

0.17

2.0

4,300

0.94

Sound Operating
Expectedpressure temperature
life
level
range
[h]
[Pa] [inchH 2O] [dB(A)]
[˚C]
40000
141.3 1,600
6.42
75
-20
at 60˚C
to(70000
+70
33.2
105
0.42
40
at 40˚C)
Max. staticpressure* Input PWM frequency: 25 kHz; speed is 0 min at 0% PWM duty cycle.
Note: The expected life at an ambient temperature of 40˚C is for reference purposes only.
-1

4. Key Points of Development

3.2.2 Airflow vs. static pressure
characteristics
F i g u r e 3 s h ow s t h e a i r f l ow v s . s t a t i c p r e s s u r e

The new model features a newly-designed impeller,

characteristics for the new model. Examples are shown for aframe, and circuit that improve static pressure and airflow

PWM duty cycle of 100% and 20% at a rated voltage of 12 V.

performance.
Next, we explain the key development points and compare

3.2.3 PWM control function

the new model with the current model.

The new model has a PWM control function that enables

4.1 Impeller and frame design

external control of fan speed.

The new model uses a structural design that can withstand3.3 Expected life

high speeds. This enables it to achieve higher static pressure

The new model has an expected life of 40,000 hours at
60°C (survival rate of 90%, run continuously at rated voltage

and airflow performance than the current model.
Figures 4 and 5 show a comparison between the newmodel and current model in terms of impeller shape andand normal humidity in free air).

frame shape, respectively.
[inchH2O]
8

[Pa]
2000

To support higher speeds, the impeller and frame need

12 VDC

to be strong enough to withstand the generated stress. To
achieve this, we used our proprietary stress simulation

100% PWM
duty cycle

1600

technology to select optimal impeller and frame shapes andStatic pressure

6

plastic strengths to maintain the needed strength.
A not her cha l lenge t hat we fac ed wa s t he h ig her

1200

temperature rise of the motor. This was due to the increase4

i n power consu mption caused by the h ig her speed.
800

2

We overcame this challenge by improving the cooling
performance by optimizing the size, quantity, and location

20% PWM
duty cycle

400of the air vents on the impeller, especially the air ventson the outer periphery of the impeller. This enabled us to0

reduce the temperature rise of the motor.
0

1
0

2
50

3
100

5 [m3/min]

4
150

[CFM]

Airflow

Fig. 3 Airflow vs. static pressure characteristicsof the new model

11

SANYO DENKI Technical Report No.51 May 2021

80 × 80 × 38 mm San Ace 80 9HVB Type High Static Pressure Fan

5. Comparison with Current Modelø17 mm air vent (Hole diameter enlarged)
Air vent (Added
to outer periphery)ø14 mm air vent

5.1 Comparison of airflow vs. staticpressure characteristics
Figu re 6 compares the ai r f low vs. static pressu recharacteristics of the new and current models. Maximum
airflow and maximum static pressure are, respectively, 1.07
times and 1.19 times that of the current model.

New model

Current modelFig. 4 Comparison of the impeller shapes
for the new and current models

5.2 Power consumption comparison
with the current model
Figure 7 provides a comparison of power consumption
for the current and new models at equivalent cooling
performance. When the speed of the new model is lowered
by PWM control to have the same cooling performance as
the current model, the new model consumes 5% less power

9 static blades

7 static blades

than the current model.
1800
Voltage: 12 V
PWM duty cycle: 100%

New model
9HVB0812P1G001

1600

Current model
9HVA0812P1G001

1.19 times
1400

New model

Current model

4.2 Circuit design

Static pressure [Pa]1200

Fig. 5 Comparison of the frame shapefor the new and current models

1000

800

The new model has the highest maximum-load power
consumption among all of our 80 × 80 mm products. In

600

particular, it is 1.6 times higher than that of our current
model. The heat generated by electronic components due tothe increase in power consumption was a problem. We tried

400

applying some conventional measures such as using multiple
components or larger components with higher current

200

capacities. These measures were effective, but not enough tosuppress the heat generation.
In addition to selecting highly efficient electronic
components, we implemented a pattern design that took into
consideration heat dissipation. This enabled us to achievea circuit design for high speed applications by optimally

1.07 times
0

0

1

2

3

4

5

Airflow [m /min]3

Fig. 6 Airflow vs. static pressure characteristics(Compared with the current model)

arranging the components so as to maximize self-cooling via
the air vents based on the improved cooling performance of
the impeller as described in Section 4.1.

SANYO DENKI Technical Report No.51 May 2021

12

80 × 80 × 38 mm San Ace 80 9HVB Type High Static Pressure Fan

2500

Masato Kakeyama

2000

Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

1500

60

1000

30

Power consumption [W]

90

5% reduction

Static pressure [Pa]

Author120
New model
9HVB0812P1G001(at equal cooling performance)
Current model
9HVA0812P1G001

Voltage: 12 V

Operating point

Yo Muramatsu
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Naoya Inada
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.
図版の文字

500

0

Yuto Horiuchi

123

Design Dept., Cooling Systems 英語版用
Div.
Condens
Works on the development and design of cooling fans.
英語版用Times Ten0

Honami Osawa
0

1

2

3

4

Airflow [m3/min]Fig. 7 Power consumption comparison
with the current model

6. Conclusion
This article has introduced the features and performanceof the 80 × 80 × 38 mm San Ace 80 9HVB type high staticpressure fan.
The new model has higher static pressure and airflow thanour current model.
With high static pressure and airflow, the new model caneffectively cooling the equipment that has high density andhigh heat generation.
We will continue to develop the industry’s best fans interms of performance, reliability, and quality by using
future-oriented technologies that enable us to quickly adapt
to the demands of customers.

13

SANYO DENKI Technical Report No.51 May 2021

Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Feature: Technical Developments in 2020

Power Systems Division
Satoru Shimizu

Fifth-generation mobile
communication system (hereinafter,“5G”) ser vices started in 2020.
5G is expected to advance IoT and
AI by enabling “high -speed andlarge-capacity” data transmission,“low latency,” and “multi-device
connections.” Edge computing
will particularly benefit from thefeatures of 5G and is expected
to be increasingly deployed in awide range of fields, including
manufacturing, ICT, and medicine.
Since edge computing enables
servers to be distributed in areas inclose proximity to user terminals,
it is expected that there will be
growing demand for uninterruptible
power supplies (UPSs) withexcellent environmental durability
and maintainability.
Many world leaders believe thatgreenhouse g as emissions are
the main cause of the increasingly
severe natural disasters that are
occurring throughout the world. As
a result, environmental initiatives arebeing taken in earnest to achievea “d e c ar b onize d so c iet y” that
reduces greenhouse gas emissions
to zero by 2050. These initiatives
are expected to increase thedeployment of renewable energy
power generation systems, suchas those that use hydroelectric,
geothermal, and biomass sources.
It is anticipated that these systems
will be able to operate stably in all
types of natural conditions despite
environmental and installation site
restrictions.
In the global market, an increasing
number of equipment are being
installed in locations where there
is an unstable supply of power. To
prevent equipment from being failed
due to power outages and prevent
harmonics generated by equipmentfrom affecting utility power, theset y p e s of l o c at i o ns n e e d to b eprovided with equipment that can
prevent instantaneous voltage dipsand harmonics. Furthermore, thesetypes of equipment are increasingly
required to meet European safety
standards.

It is against this backdrop that thePower Systems Division released
the following new products in 2020.
For starters, the division expanded
its lineup of SANUPS E11B smallcapacity hybrid UPSs to include
a 3 kVA model. Furthermore, thedivision developed the SANUPS
E11B-Li lithium-ion battery equippedhybrid UP S and the SANUPS
A11M-Li parallel redundant double
conversion online UPS.
In terms of products for renewableenergy, the division developed the
SANUPS W75A as a rectifier unitthat conver ts the AC output ofgenerators, such as those of wind
power and hydro power generation
systems of 10 kW or less, into DC
power.
The division also expanded its
lineup of SANUPS C23A voltage dip
compensators to include models
that comply with European safety
standards.
This article provides an overview
of each of these products.

SANYO DENKI Technical Report No.51 May 2021

14

Feature: Technical Developments in 2020

■ Expanding the Lineup of the SANUPS E11B Hybrid UPS
T he SA NUPS E11B hybrid U PS

product has an input frequency range

constantly monitors the status of thefrom 40 to 120 Hz. This enables it

input power source and automaticallyto be installed in environments withselects the optimal power supply mode

unstable power conditions. This also

to provide a stable supply of high-re duc e s t he a mou nt of sw itch i ng

quality power. This UPS achieves both

operations required during battery

high-quality power supply and energy

usage and prevents battery depletionsavings.

and degradation.

We added a 3 kVA model to ourFu r ther more, its env i ron menta loriginal lineup of 1 kVA, 1.5 kVA (1),temperature range of -10 to +55˚C

and 2 kVA products.

a l lows the u n it to be i nsta l led i n

Figure 1 shows the appearance of the
SANUPS E11B.
The SANUPS E11B has a wider input
range than previous models.

Fig. 1 SANUPS E11B

environ ments susceptible to large
temperature changes.
A det a i le d i nt ro du c t ion of t heperformance, functions, and features ofT he input specifications include

the SANUPS E11B is provided in the

input voltage ranges of 55 to 150 V

New Products Introduction section of

for the 100 V model and 110 to 300 V

this Technical Report.

for the 200 V model. In addition, this(1) 1.5 kVA model is available for 100 V only.

■ Development of the SANUPS E11B-Li Hybrid UPS

and the SANUPS A11M-Li Double Conversion Online UPS

The SANUPS E11B-Li and SANUPS

Since the expected life of lithium-ion

A11M-Li are UPSs that come equippedbatteries is 10 years, we simply revisedwith lithium-ion batteries.

the lead-acid battery specifications

Figure 2 shows the appearance of the
SANUPS A11M-Li.

of the SANUPS E11B and SANUPS
A11M to enable them to use lithium-

The SANUPS E11B-Li is available inion batteries to achieve 10 years of

1 kVA, 1.5 kVA , and 2 kVA products.

mai ntenance-f ree operation. T h is

T he S A N U P S A 11M - Li ca n bemeans that these units contribute toexpanded to 8 kVA by combining 1 kVA

both cost and labor savings.

(1)

units. Moreover, by using one of the

T he input specifications andunits as a backup unit, operators canenvironmental temperature range areconfigure a parallel redundant system

the same as those of the SA NUPS

capable of supplying highly reliable

E11B and SANUPS A11M. Therefore,

power.

they can be installed in environments

T he input voltage specifications
include a lineup of single-phase 2-wirewith unstable power supply conditions
or large temperature changes.

100 V and 200 V products(1).
(1) 1.5 kVA model is available for 100 V only.

15

SANYO DENKI Technical Report No.51 May 2021

Fig. 2 SANUPS A11M-Li

■ Development of the SANUPS W75A Rectifier for Wind Powerand Hydro Power Generation Systems

The SANUPS W75A is a rectifier

The main feature of this unit is its

for w i nd p ower a nd hyd ro p ower

DC voltage rise control function (brake

generation systems.

f u nction). T h is f u nction prevent s

Figure 3 shows the appearance of the
SANUPS W75A.
The SA NUPS W 75A has a rated
output capacity of 11 kW.

voltage above the specification range
f rom b ei ng appl ie d to t he p ower
conditioner. With a sealed structureand fanless passive air cooling system,

T he ma i n ci rcu it uses f u l l-wave

the SANUPS W75A achieves excellent

rectification to convert the AC power

environmental durability via I P65

of the generator into DC power that canwater and dust protection.

be input to the power conditioner. It

Since it comes with a wide AC input

achieves the industry’s highest level ofvoltage range and DC output voltage

conversion efficiency(2).

range, it can be f lexibly used as a

The SANUPS W75A was developed

rectifier for renewable energy power

to be used in combination with ourgeneration systems that use generators,

three-phase 9.9 kW SANUPS W73A

such as those that use biomass andpower conditioner for wind power andgeothermal power sources as well ashydro power generation systems.

wind and hydroelectric.

Fig. 3 SANUPS W75A

(2) Based on our own research as of January 29, 2020, conducted among 3-phase rectifiers
for wind power and hydro power generation systems.

References
Ryu Yoshizawa and 3 others: Development of the SANUPS W75A Rectifier Unit for Wind Powerand Hydro Power Generation Systems
SANYO DENKI Technical Report, No.50, pp.21-24 (2020.11)

SANYO DENKI Technical Report No.51 May 2021

16

Feature: Technical Developments in 2020

■ Expanding the Lineup of the SANUPS C23A Voltage Dip Compensator
T he SA NUPS C 23A voltage dip

Our new lineup of 50 kVA, 100 kVA,compensator is available in a lineup

and 200 kVA SANUPS C23A productsof 10 kVA, 20 kVA, 30 kVA, 50 kVA,c ompl ies w it h Eu ropea n sa fet y

100 kVA, and 200 kVA products.

standards, including the Low Voltage

Figure 4 shows the appearance of the
SANUPS C23A (200 kVA model).

Directive, EMC Directive, and RoHS
Directive.

T he SA N UP S C 2 3A c a n supply

This means that these products canstable power to equipment without

be used as equipment power supplies

i nter r uption even when there a renot only in Japan, but in many countries

i nsta nta neous voltage d ips or

throughout the world.

momentary outages. Furthermore,

A det a i le d i nt ro du c t ion of t heit uses a n act ive f i lter to prevent

performance, functions, and features ofharmonics from affecting utility power.

the SANUPS C23A is provided in theThis power supply unit can use these

New Products Introduction section offeatures to supply highly efficient andthis Technical Report.

high-quality power using a parallel
processing topology (parallel inverterfeed).

Author

Satoru Shimizu
Design Dept., Power Systems Div.
Works on the development and designof UPS.

17

SANYO DENKI Technical Report No.51 May 2021

Fig. 4 SANUPS C23A
(200 kVA model)

New Product Introduction

Development of the SANUPS C23A
Voltage Dip Compensator with
Compliance with European Standards
Hiroaki Miyoshi

Yuji Wada

Minoru Yanagisawa

Yuzo Kubota

Naoya Nakamura

Takuya Ota

Satoshi Furihata

Shohei Ohashi

1. Introduction

the bi-directional inverter supplies only the necessary power
for the harmonic current suppression and input power factor

In recent years, an increasing number of industrial

correction. This significantly reduces power loss and makes

equipment manufacturers in Japan have introduced

a high-efficiency and high-quality power supply possible.

semiconductor manufacturing facilities in China and other

If the grid power fails, the C23A immediately isolates

Asian countries. Taking unstable local power environments,

the grid power and continues supplying power from the bi-

these facilities often need to be combined with a voltage dip

directional inverter without interruption. (1)compensator and harmonic solution equipment.
Our existing product, the SANUPS C23A voltage dip
compensator, can be used for such needs to reduce the initialcost and installation man-hours because, with its active
filter, it can solve the voltage dip problem and harmonics
problem in one unit. (1)Furthermore, the equipment installed in the factories
in China and other Asian countries has been increasingly
required to have CE markings to comply with European
safety standards.
To meet this need, we newly developed CE-compliant
models of the SANUPS C23A voltage dip compensatorand added them to the lineup. This article introduces theFig. 1 SANUPS C23A (200 kVA model)features of this new model.

2. Product Overview

Maintenance bypass circuit

The new models of the SANUPS C23A have capacitiesof 50, 100, and 200 kVA.

AC input
AC switch

Figure 1 shows the appearance of the 200 kVA model,
and Figure 2 shows the basic circuit block diagram of the

EDLC

Bi-directional
inverterAC output

SANUPS C23A.
The SA NUPS C23A features a parallel processing
topology and uses an electric double-layer capacitor

Fig. 2 Basic circuit configuration(EDL C) as a n energ y storage dev ic e. T he pa ra l lel
processing topology supplies power to loads mainly via an
AC switch. When it does this, the bi-directional inverter
configures redundancy in parallel with the grid powerand charges the EDLC while the active filter suppresses

3. Features
3.1 Compliance with international safety
standards

harmonic currents and corrects the input power factor. In

The new models of the SANUPS C23A are compliant withother words, the grid power supplies power to the load, while

European safety standards of the Low Voltage Directive

SANYO DENKI Technical Report No.51 May 202118

(2014/35/EU), EMC Directive (2014/30/EU), and RoHS
Directive (2011/65/EU, (EU) 2015/863), with most of theMaintenance bypass circuit

features of the current models maintained. Therefore, they
can be used in countries and companies that require CE

AC input
AC switchmarking.
In particular, the customers who have used the existing

EDLC

SANUPS C23A as a power supply for semiconductor

Bi-directional
inverter

EDLC discharge
circuit breaker

Switched on

manufacturing equipment in Japan can now use the same
system overseas without the need to design or purchase a

AC output

Discharge EDLC by switching
the bi-directional inverter

new power supply system.

(1) Step 1

3.2 Extended expected life
The expected life of the current models of the SANUPSC23A is 10 years. However, the new models have a longer

Maintenance bypass circuit

expected life of 15 years with a new electrolytic capacitor
and other components used. Components that last less thanAC input
AC switch

15 years, such as the EDLC, fans, fuses, and electromagnetic
contactors, are classified as periodic replacement parts,

EDLC

Bi-directional
inverter

specifying the maintenance cost for customers who intend to

EDLC discharge
circuit breaker

Switched off

use the product for 15 years.

3.3 Improved maintainability

Discharge EDLC
with discharge resistor

EDLC discharge
resistor

The new models have an expected life of 15 years.

AC output(2) Step 2

However, as described in Section 3.2, this requires that somecomponents be replaced periodically. For easy replacement

Fig. 3 Self-discharge of EDLC

work, we have revised the layout of components andthe mounting structure. In addition, we also revised theelectrolytic capacitor in the bi-directional inverter unit sothat it would last for 15 years and require no replacement.
This helped reducing the replacement time and costs.

3.4 Dimensions
Table 1 compares the dimensions of the new SANUPSEDLCs have a service life of about 10 years, so they

C23A models with current models. For the new models,

would be subject to replacement. However, similar to lead-

we added a circuit to conform to the EMC Directive andacid batteries, an EDLC remains charged with a certain

secured insulation by providing more clearance between

voltage stored even after the power is disconnected.

components to conform to the Low Voltage Directive.

Replacing the EDLC in this state could cause an electric

Although the new 200 kVA model has a 100 mm longer

shock or short circuit. To prevent this and ensure safe EDLC

width than that of the current 200 kVA model, we managed

replacement, we added the new models with a new function

to maintain the dimensions of our current models for 50 andfor discharging the EDLC. The EDLC discharge proceeds

100 kVA capacities by revising the component layout andin two steps. The first step is shown in Figure 3 (1). This

other efforts. This means that the current models can easilyrequires consuming the charge that remains in the EDLC so

be replaced with the new models.

that it falls below a dangerous level (60 VDC). This is done

Table 1 Dimensions

by using the bi-directional inverter’s no-load loss that resultsfrom switching the bi-directional inverter. The second stepis shown in Figure 3 (2). This requires connecting a resistor

Outputcapacity

to the EDLC discharge circuit breaker after stopping the

50 kVAunit, and then turning on the circuit breaker to discharge the
EDLC to almost no voltage. After these steps, technitians

100 kVA

can safely and quickly replace EDLCs and perform
necessary maintenance work.

19

SANYO DENKI Technical Report No.51 May 2021

200 kVA

Model no.

Size (width × depth × height)
Unit: mm

C23A503C (New model)

750 × 700 × 1775

C23A503 (Current model)

750 × 700 × 1775

C23A104C (New model)

1050 × 800 × 1950

C23A104 (Current model)

1050 × 800 × 1950

C23A204C (New model)

1650 × 800 × 2075

C23A204 (Current model)

1550 × 800 × 2075

Development of the SANUPS C23A Voltage Dip Compensator with Compliance with European Standards

4. Specifications
Table 2 shows the electrical specifications of the new
product.

Table 2 Electrical specifications
Model no.

Items
Rated
Apparent power
outputcapacity Active power

C23A503C

C23A104C

C23A204C

50 kVA

100 kVA

200 kVA

40 kW

80 kW

160 kW

Enclosure type

Steel-sheet free-standing enclosure (Ingress
protection rating: IP2X)

Topology

Parallel processing

Cooling system

Forced air cooling

Energy storage device

AC
input

Electric double-layer capacitor (EDLC)

No. of phases/wires

3-phase 3-wire

Rated voltage

200/210/220 V

Rated frequency
Current harmonic
distortioncompensation

50/60 Hz
Compensation capacity

Within rated capacity

Harmonic current

85% or higher compensation

Compensation order

2nd to 20th harmonics

Input power factor

0.98 or greater

No. of phases/wires

3-phase 3-wire

Rated voltage

200/210/220 V

Voltage regulation

Load power factorAC
outputAt 100% rectifier load
At rated output

In grid operation

Within -8 to +10% of rated voltage

User-selectable

In capacitor operation

Within ±2% of rated voltage(1)

Rated frequency
Frequency regulation

Remarks

50/60 HzIn grid operation

Within ±4% of rated frequency

In capacitor operation

Within ±0.1 Hz of rated frequency

Rated

0.8 (lagging)

Fluctuation range

0.7 to 1.0 (lagging)

Voltage harmonic
At linear load
distortion(In capacitor operation) At rectifier load
Voltage unbalance (In capacitor operation)

2% or lessTransient voltage
fluctuation(In capacitor operation)

Fluctuation

Within ±5%

Settling time

50 ms or less

(1)

(2)

5% or less
2% or lessWith a load of 1/3 the total capacity on one line

Overload capability (Bypass circuit)

200% (for 30 s), 800% (for 0.5 s)

Overcurrent protection

The inverter shuts down at 110% of the rated output, then the grid power will be supplied bybypass.
When the current falls equal to or below the rated current, the inverter will automatically startup for normal operation.

Transfer time to capacitor operation

0 s (No interruption)

Dip compensation time

1 s or more (At rated load)(3)

Initial charging time

Within 60 s

Capacitor voltage from 0 to 100%

Recharging time

Within 10 s

After compensating for a 1-second voltage dip

Acoustic noise

65 dB or lessA-weighting, at 1 m from front of unit

Heat dissipation

2.6 kW

Operating environment

Ambient temperature: 0 to 40˚C
Relative humidity: 30 to 90% (non-condensing)Standards

CE (Low Voltage Directive, EMC Directive): EN 62040-1, -2, RoHS Directive

5.1 kW

10.2 kWAt rated output, after battery charging
completed(4)(1) When switched to the capacitor operation with the rated input voltage and rated frequency; indicates the performance of the inverter.
(2) In continuous operation(3) At the rated load level, a load power factor of 0.8 lagging and 25˚C ambient temperature.
(4) Calculated with a load power factor of 0.8.

SANYO DENKI Technical Report No.51 May 2021

20

Development of the SANUPS C23A Voltage Dip Compensator with Compliance with European Standards

5. Conclusion
This article introduced the features of our new CEmarking compliant models of the SANUPS C23A voltage
dip compensator.

AuthorHiroaki Miyoshi
Design Dept., Power Systems Div.
Works on the development and design of UPS.

Compared to the current models, the new models have thefollowing added advantages:

Yuji Wada(1)	C ompliance w ith the follow ing Eu ropean safety

Design Dept., Power Systems Div.
Works on the development and design of UPS.

standards: the Low Voltage Directive, EMC Directive,
and RoHS Directive(2) Extended service life and improved maintainability
With these advantages, the new models can meet theneeds of customers who require CE marking compliance

Minoru Yanagisawa
Design Dept., Power Systems Div.
Works on the development and design of UPS.

for use in Asia and Europe. In addition, they can reducethe initial investment and maintenance costs for these

Yuzo Kubota

customers.

Design Dept., Power Systems Div.
Works on the mechanism design of UPS.

Moving forward, we will continue to keep up with theneeds of customers to swiftly develop products that cansatisfy them.

Naoya Nakamura

References

Design Dept., Power Systems Div.
Works on the development and design of UPS.

(1) Shoichi Ota and 7 others: Development of the High Performance
Voltage Dip Compensator SANUPS C23A

Takuya Ota

SANYO DENKI Technical Report, No.27, pp.15-20 (2009.5)

Design Dept., Power Systems Div.
Works on the development and design of UPS.

Satoshi Furihata
Design Dept., Power Systems Div.
Works on the development and design of UPS.

Shohei Ohashi
Design Dept., Power Systems Div.
Works on the development and design of UPS.

21

SANYO DENKI Technical Report No.51 May 2021

New Product Introduction

Development of the SANUPS E11B
Hybrid UPS
Akihiro Tsukada

Hiroyuki Hanaoka

Hiroshi Sakaba

Kazuya Nishizawa

Yuhei Shoyama

Takuya Ozawa

Hidenori Takizawa

Yuki Takayama

1. Introduction
In recent years, the demand for uninterruptible power

the features of the SANUPS E11A series, while alsosignificantly reducing costs and providing compatibility withthe global market.

supplies (UPSs) has been increasing throughout the world.
One of the reasons for this is because the spread of mobile
devices and IoT-ready equipment has required more robust
backup systems. As such, UPSs that can operate in regionswith unstable power grids have been demanded.
Furthermore, there is also growing demand to reducecarbon footprints* as a countermeasure to global warming

3. Features
Figure 1 shows the appearance of the 1 kVA model ofthe SANUPS E11B. The series lineup is available in output
capacities ranging from 1 to 3 kVA. Its appearance andfeatures are identical to the E11A series.

in order to help facilitate a sustainable society. As a result,the market is requiring products that can reduce CO 2
emissions and achieve energy savings over their entire
service life.
It is against this backdrop that we have developed the
SANUPS E11B as the successor series to our SANUPS
E11A series, with an eye on overseas markets. This article
will provide an overview of this series.
* A carbon footprint is the total amount of greenhouse gas
emitted throughout its life cycle, including procurement of raw
materials, production, use, disposal, and recycling, calculated
in CO2 equivalents. It can be one of the product parameters for
product selection.

Fig. 1 SANUPS E11B 1 kVA model

3.1 UPS topology
The SA NUPS E11B series comes with two modes,
namely, a Double Conversion mode and Economy mode.

2. Development Background

The modes can be used differently depending on thesettings. When the setting is fixed to Double Conversion

Our current SANUPS E11A series makes use of a double

mode, the inverter always supplies high-quality power.

conversion online topology to supply high-quality power, as

When set to automatic, the UPS will switch between thewell as a passive standby topology that prioritizes efficiency.

Double Conversion mode and Economy mode depending on

It is available in output capacities of 1 kVA, 1.5 kVA, 2 kVA,

the state of the input power, achieving both the high-quality

and 3 kVA. Although this series comes with many desirable

power and energy savings. The modes are described below.

features, UPSs in this capacity range have, in recent years,
been facing tough competition in terms of cost both in Japanand abroad.

(1) Double Conversion mode (High-quality power mode)
Figure 2 shows the power supply path for the Double

At the same time, there has been greater urgency to

Conversion mode. First, the grid power is rectified andaddress environmental issues on a global scale, thereby

converted to a DC voltage. This is then converted by theincreasing demand for environmentally-friendly products.

inverter to a sinusoidal voltage and output. Therefore,

Against such a backdrop, we developed the SANUPS

even when the grid power fluctuates, the fluctuation is

E11B as an environmentally-friendly series that inherits

absorbed by the rectifier and inverter, enabling the UPS

SANYO DENKI Technical Report No.51 May 2021

22

to keep supplying high-quality power. The batteries areoutage, the rectifier and charger will be stopped, then theconstantly float-charged by the charger so that they stay

converter will operate to supply power from batteries.

charged and ready for a power grid failure such as a power

If a grid failure occurs during the Double Conversion

outage or voltage dip. If the grid frequency is within themode, battery power will be supplied to the load without

frequency synchronization range (within ±1% when set tointerruption. If a grid failure occurs during the Economy

the Double Conversion mode fixed; when set to automatic,

mode, there will be an interruption within 8 ms until battery

the range depends on the synchronization range setting),

power will be supplied.

the UPS outputs a voltage with a frequency synchronizedwith the AC input frequency. If it is outside the range, it
outputs a constant frequency of 50 Hz or 60 Hz and does notsynchronize with the input voltage.

Grid
power
RectifierCharger

OutputBattery

Fig. 4 The power supply path
during a power grid failure

InverterConverter

Charger

InverterConverter

OutputGrid
power
RectifierOutputBattery

3.2 Wider input voltage and frequency
rangesFig. 2 The power supply pathfor the Double Conversion mode

We revised the converter’s circuit type and control method
to widen the operating input voltage range and frequency(2) Economy mode (High-efficiency mode)

range.

Figure 3 shows the power supply path for the Economy

The SANUPS E11B series support two voltage classes:

mode. When the grid power is stable, the inverter stops,

100 V and 200 V (1.5 kVA capacity is only available in theallowing the grid power to be output as is. This eliminates

100 V class). For the 100 V class, the E11A’s 80 to 115 V

the loss through the inverter and increases efficiency. The

input voltage range has been
widened to 55 to 150 V. For
図版の文字

batteries are constantly float-charged by the charger so

the 200 V class, the previous 160 to 230 V range has beenthat they stay charged and ready for a power grid failure

widened to 110 to 300 V. AsCondens
for the input frequency range,such as a power outage or voltage dip. When the grid power

the previous E11A’s ranges of
46 to 54 Hz at 50 Hz and 55.2
英語版用

becomes unstable, the UPS automatically transfers to theto 64.8 Hz at 60 Hz have been widened to 40 to 120 Hz at

Double Conversion mode described in the (1) above. This

50/60 Hz.

123

英語版用

Times Tenis done without interruption if the input frequency is within

This reduces the number of unnecessary transfers to

the synchronization range, or there will be an interruption

battery power and prevents battery wear and degradation

within 8 ms if it is outside the range.

when the unit is used in areas with flactuating grid power.

In the Economy mode, it is necessary to immediately
detect abnormalities in the grid power. This is ensured bymonitoring the input voltage waveform.

3.3 Wider operating temperature range
To improve the cooling efficiency, we reduced the amountof wiring and revised the component layout to ensure

Grid
power

OutputRectifierInverterConverter

Charger

Battery

Fig. 3 The power supply pathfor the Economy modesufficient air passage. We also selected components that canbe used at low temperatures. These revisions have expanded
the operating temperature range from 0 to 40˚C to -10 to
55˚C.
With a wider operating voltage range, the new productcan be used in more harsh environments where the previous
product could not be used.

3.4 Modular input and output(3) In the event of a power grid failure

It was expected that there would be situations where it

Figure 4 shows the power supply path during a power grid

would be necessary to change the input plugs or power

failure. If the power grid causes an interruption or power

outlets when the product would be used in overseas markets.
図版の文字

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SANYO DENKI Technical Report No.51 May 2021

123

英語版用

CondensDevelopment of the SANUPS E11B Hybrid UPS

To be prepared for this, we modularized the input anddecided not to include them and instead to have the latest

output part and gave it a structure that could be removed

software version downloaded from our website. This helps

from the main UPS unit. This aimed to allow the input andreduce the amount of plastic waste. As for the Instruction

output parts to be changed independently, which would be

Manual, we used to provide a booklet with UPSs. However,much faster and easier than redesigning the entire UPS.

we now only provide a simplified version that gives the

Figure 5 shows the rear view of the 1 kVA model of theminimum necessary instructions. Electronic versions of full

SANUPS E11B, and Figure 6 shows its internal structure.

Instruction Manuals have been made available for download

The area enclosed by the border is the modularized input

from our website. This has the advantage of allowing

and output part.

customers to always download and use the latest version asneeded without creating extra waste.
For the packaging, we changed the packaging material
from styrofoam to corrugated cardboard to reduce theamount of plastic use for less impact on the environment.

Fig. 5 Rear view of the SANUPS E11B 1 kVA model

4. Specifications
Table 1 shows the standard specifications of the SANUPS
E11B 1 kVA model.

5. Conclusion
Input and
output partIn this article, we introduced the SANUPS E11B, thesuccessor series to our SANUPS E11A hybrid UPS series.
With widened input ranges, the new product can be used
図版の文字

around the world with peace123of mind even in areas withunstable power grids and in harsh
operating environments.
英語版用

Moreover, we reduced theCondens
amount of wiring for easier
英語版用recycling, while also changing
theTenpackaging material andTimes
how we provide the software and Instruction Manual to
make the product more environmentally friendly.
We will continue to develop products that can meet theFig. 6 The internal structureof the SANUPS E11B 1 kVA model

3.5 Reduced internal wiring
As shown in Figure 6, we directly connected PCBs to eachother using connectors and reduced the amount of wiringneeds of our customers by grasping their needs accurately
in a timely manner and contribute to creating value for theirbusinesses.
References(1) Hiroyuki Hanaoka and 6 others: Development of the SANUPS
A11M Small-Capacity UPSs

by replacing it with PCB patterns as much as possible. The

SANYODENKI Technical Report, No.48, pp.22-25 (2019.11)

reduction in wiring not only reduced assembly man-hours(2) Hiroshi Sakaba and 5 others: Development of the Hybrid UPS

and material costs, but also secured internal clearances for

SANUPS E11A

air passage required for cooling.

SANYODENKI Technical Report, No.21, pp.14-18 (2006.5)

This also aimed to make disassembly and recycling easierat the end of the product life, minimizing the impact on theenvironment.

3.6 Environmentally friendly
Previously, we used to include a power management
software CD-ROM with UPSs. However, CD-ROMs
become no longer necessary after installation, so we

SANYO DENKI Technical Report No.51 May 2021

24

Table 1 Standard specifications of the SANUPS E11B 1 kVA model
Items
Model
Output capacity
Cooling system
Input plug
Number of phases/wires

AC
input

Ratings and standards
E11B102
E11B102
100 V class
200 V class
1 kVA / 0.8 kW
Forced air coolingIEC 60320-C14
Single-phase 2-wire
55 to 150 V

110 to 300 V

When in Double Conversion mode
The range varies by the load level.

Within ±8%
of 200/208/220/
230/240 V

When in Economy mode

Rated frequency

Within ±8%
of 100/110/
115/120 V
40 to 120 Hz

Required capacity

1.1 kVA or less

Input power factor
Output outlet
Number of phases/wires

0.95 or greater
NEMA 5-15R × 6
Single-phase 2-wire

Rated voltage

100/110/115/120 V

Rated voltage and range

Max. capacity during battery recovery
charging
At rated output
IEC 60320-C13 × 6

Voltage regulation

200/208/220/
230/240 V
Within ±2% of rated voltage

Rated frequency

50 Hz or 60 Hz
Within ±1% of rated frequency

Frequency regulation
Within ±1, 3, or 5% of the rated frequency
Voltage waveformAC
outputVoltage harmonic distortion

Sinusoidal
At linear load: 3% or less
At 100% rectifier load: 8% or less

For abrupt loadchangeTransient
Loss or return
voltage
Within ±5% of rated voltage
of input powerfluctuation
Abrupt input
voltage change
Response time
5 cycles or less
Load power factor
0.8 (lagging)
Automatic transfer to bypass circuit
Overcurrent protection
at 105% or more
Inverter
105%
Overload
15 A
8A
protection Bypass(current protector)(current protector)
Small-sized valve-regulated lead-acid
Type(VRLA) battery
No. of batteries
2
Battery
Rated capacity
68 W
3 min (800 W)
Backup time
5 min (700 W)
25 W
Heat dissipation
130 W
Input leakage current
Environment

3 mA or lessAmbient temperature: -10 to +55˚C
Relative humidity: 20 to 90%
40 dB or lessAcoustic noise
48 dB or less25

Remarks

SANYO DENKI Technical Report No.51 May 2021

User-selectable
When in Double Conversion mode
Same as the input frequency(auto-select)
In Double
Conversion mode
In battery
fixed setting
operation:
Within ±0.5%
In “automatic”
setting
At rated output
0 ⇔ 100% load step changes
at rated input
At rated output
For ±10% changes
Variation range 0.7 (lagging) to 1.0
With automatic retransfer function
200 ms
200% for 30 s, 800% for 2 cycles(reference values)

12 V per battery, serial
15-minute rate, 34 W per battery
At a 25˚C ambient temperature,using new, fully charged batteries.
When in Economy mode
When in Double Conversion mode,
after battery charging completedBatteries stop charging
at temperatures above 40˚C
When in Economy
1 m frommode
front of UPS,
When in Double
A-weighting
Conversion mode

Development of the SANUPS E11B Hybrid UPS

AuthorAkihiro Tsukada
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Hiroyuki Hanaoka
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Hiroshi Sakaba
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Kazuya Nishizawa
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Yuhei Shoyama
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Takuya Ozawa
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Hidenori Takizawa
Design Dept., Power Systems Div.
Works on the mechanical design of power supplies.

Yuki Takayama
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

SANYO DENKI Technical Report No.51 May 2021

26

Feature: Technical Developments in 2020

Servo Systems Division
Yasutaka Narusawa

SA NYO DENK I contributes tosociety by developing new productsthat help enhance the performancea n d q u a l i t y of o u r c u s to m e r s’equipment and create new value.
T hi s a r t i c l e w i l l i nt ro d u c e t h e
features and innovative points ofthe ser vo systems products wedeveloped in FY2020, and describe
how they are contributing to ourcustomers and society.
In par ticular, we will discuss
wireless communication products
for motion controllers and servo
amplifier products.
For star ters, we developed
the Wireless Ad a pter 3A . T his
device adds wireless features to
the SANMOTION C S100 motionc o nt ro l l e r ( h e re i n a f te r, S10 0 ).
I t m ake s i t e a s y to w i re l e s sl yc ommunic ate using a wireless
L AN or smartphone in a factoryby simply mounting it to the USB
c o nne c to r of the S10 0 m oti o ncontroller and setting a few minimal

27

parameters. It also complies withthe radio laws and regulations ofmany countries, so it can be used atvarious overseas production sites.
In recent years, IoT has been
advancing at production sites withthe aim of improving productivity
and predic ti ve maintenance ofequipment. This product contributes
t o t h e a d v a n c e m e n t o f I oT a t
production sites by making it easy
to collect various types of data frommachinery and servo control devices
via wireless communication.
In the field of AC servo amplifier
products, we enhanced our
SAN M OTIO N R 4 0 0 VAC input
multi-axis servo amplifier lineup
to suppor t output capacities
ranging from 20 k W to 37 k W.
The new models are smaller andm o re l i g ht we i g ht , a c hi ev i n g a
61% reduction in volume and 60%
reduction in mass compared toprevious models. This was done byadopting a high-density component

SANYO DENKI Technical Report No.51 May 2021

layout and optimizing the heatdissipation design.
We have also developed an
EtherCAT interface type control
unit based on our SANMOTION R
3 E Model ser vo amplifier. T hecontrol unit can help improve theperformance and processing qualityof machinery.
By combining these products with
our previously developed 15 kW
system, we were able to create a
400 VAC multi-axis servo amplifier
lineup of products capable of driving
motor s w ith out put c a p ac ities
ranging from 550 W to 37 kW. As
a result, we were able to complete
a lineup that supports the same
outputs as that of our 20 0 VAC
multi-axis servo amplifier. This gives
customers an even greater choiceof products to meet their various
machinery needs.
Below are overviews of the new
products and their features.

■ Wireless Adapter 3A
In recent years, factory networks
h ave b e e n s w it c h i n g t o w i r el e s seach other even in areas where there ismade to production lines.

no available wireless network.

4. Improved maintainability

LA Ns to enable f lexible changing
t he d iver s e ne e d s of c o n s u mer s .

2. Compliance with regulations
in various countries

operators to access machinery due toFurthermore, the use of IoT in factories

T h is product c ompl ies w ith thetheir installation location. This producthas been accelerating as a method forIEEE802.11b/g/n wireless standard,facilitates maintainability even in thesecollecting and analyzing information

a l low i ng for fa ster a nd fa r t her

types of environments by enablingfrom production sites with the aim oftransmission. It can also be used at

operators to diagnose machine failures

improving productivity and predictive

various overseas production sites,

and adjust servo systems from remote

maintenance of equipment.

since it complies with the radio laws

locations.

of production lines to accommodate

It can someti me be dif f icu lt for

Against this backdrop, we developed

and regulations of many countries,

As described above, this product is

the Wireless Adapter 3A as a productincluding Japan, the United States,

a wireless device that makes it easy tothat can add wireless communication

European nations, and China. Thisconnect machinery to a wireless LAN

features to the S100 motion controllermeans that wireless equipment canin a factory. It can contribute to theand be used at various production sites

be standardized without having toconstruction of flexible production

overseas.

worry about replacing devices at eachlines and improve maintainability.

The features of this product are as

location.

follows.

1. Easy network connection

3. Flexible modificationof production lines

T h i s p ro du c t c a n c o n ne c t t o a

On production lines, various devices

wireless LAN in a factory by simply

and equipment are wired together using

mounting it to the USB connector ofcables to communicate information.

the S100 motion controller and setting

When a production line changes, ita few minimal parameters. Since it also

can take a lot of time to perform thecomes with an access point mode thatrewiring work. The use of this productenables it to act as a master station, it

eliminates the need to perform wiring,allows wireless devices to connect toallowing for f lexible changes to be

SANYO DENKI Technical Report No.51 May 2021

28

Feature: Technical Developments in 2020

■ SANMOTION R 400 VAC Input Multi-axis Servo Amplifier (37 kW, 300/600 A)
In recent years, the expansion of

from 550 W to 37 kW.

industrial globalization has increased

As for control units, we released

better than previous products. It also

the need for servo systems with 400

an EtherCAT interface type control

comes with functions for monitoring

VAC input specifications, primarily

unit based on our SANMOTION R

t he st at u s of p ower c on su mpt ion

in European and Asian regions. In

3E Model. This control unit can also

a n d c o m mu n i c a t i o n q u a l it y a n d

response to this demand, we released

be used with 200 VAC systems. Thisfor estimating the remaining life of

the SANMOTION R 400 VAC input

means that the host controller can be

dynamic brake (DB) relays and holding

multi-axis servo amplifier in 2018 asshared between 200 VAC and 400 VAC

brakes. These capabilities and featuresa product that can support output

systems.

contribute to improving machinery

capacities up to 15 kW. Since its release,it has gained much popularity amongcustomers.

productivity and processing quality

2. Downsizing
and weight reduction

a nd c a n a l so b e u se d to p er for mvarious diagnostics and preventiveMore recently, we have expanded

The products have achieved a smaller

our lineup by developing a 400 VAC

size by using the latest power modules

input multi-axis servo amplifier thatand adopting an optimized thermal

D et a i l s o n t he s e new p ro du c t s

can support output capacities up to

design and high-density componenta re prov ided i n t he New P roduct37 kW, as well as a new EtherCAT

layout. They also use fewer components

Introduction section of this Technicalcommunication type control unit.

a nd ach ieve weig ht sav i ng s . I n

Report.

The features of these products are as
follows.

particular, the 600 A amplifier unit ismuch smaller and more lightweight,
achieving a 61% reduction in volume

1. Expanded lineup

and 60% reduction in mass compared

We developed a 37 kW power supply

to our previous model. Furthermore,unit as well as 300 A and 600 A servo

we de sig ne d t he st r uc t u re of t heamplifier units capable of driving

heat si n k to suppres s c omponent

servomotors with output capacities

temperatu re cha nge a nd i nc rea se

ranging from 20 kW to 37 kW. By

product reliability, while also achieving

combining these products with oura smaller size.

previously developed 15 kW system, wewere able to create a 400 VAC input
multi-axis servo amplifier lineup of

3. Increased control unit
performance

products capable of driving motors with

The new EtherCAT control unit has

extensive output capacities ranging

better servo response and suppresses

AuthorYasutaka Narusawa
Servo Systems Division
Works on the design and developmentof servo ampliﬁers.

29

mach i ne resona nc e a nd v ibration

SANYO DENKI Technical Report No.51 May 2021

maintenance.

New Product Introduction

Development of the SANMOTION R
400 VAC Input Multi-axis
Servo Systems (37 kW, 300/600 A)
Masaaki Mizusawa

Mitsuru Takasugi

Hiroto Noguchi

Satoshi Hiramitsu

Noriaki Kasuga

Shuhei Nakazawa

1. Introduction
The SANMOTION R 200 VAC input multi-axis servo
system developed in 2013 is available in a wide range ofimprove machinery processing quality and productivity,
we developed an EtherCAT interface control unit thatmaintains the performance and features of our existing
SANMOTION 3E Model.

models for driving servo motors with output capacities

In this article, we introduce the features and keyof 550 W to 37 kW. Since its release, it has gained muchdevelopment points of the new models: a single-axis

popularity among customers.

EtherCAT control unit, 37 kW power supply unit, and 300 A

In recent years, the expansion of industrial globalization

and 600 A amplifier units.

has increased the need for systems that support 400 VAC
input power, primarily in European and Asian regions. In
response to this demand, we released 400 VAC input multiaxis servo systems that support output capacities up to
15 kW in 2018.

2. Product Overview
2.1 Appearance and dimensions
Our SANMOTION R 400 VAC input multi-axis servo

We developed new models for the 400 VAC input multi-

system consists of a control unit, power supply unit, andaxis servo system for driving 20 kW to 37 kW large-output

amplifier unit, allowing for flexible system configurations.

servo motors. As a result, we now offer an expanded

The units are shown in Figures 1 and 2, while theirlineup of 400 VAC multi-axis servo amplifiers that candimensional drawings are shown in Figures 3 to 5.

drive 550 W to 37 kW output motors. Furthermore, to37 kW

Fig. 1 Appearance(Single-axis EtherCAT control unit)

300/600 A

Fig. 2 Appearance(Power supply unit and amplifier unit)

SANYO DENKI Technical Report No.51 May 202130

Ether CAT i nter fac e model desig ned ba sed on ou r

140

existing SANMOTION R 3E Model servo amplifier. We

200 ±1

95 ±1

4-ø9

27.5

180 ±1
10

For the control u n it, we added a new si ng le-a x is

also released a 37 kW power supply unit as well as 300 A and325

When using multiple control units, the units can beconnected to each other with connectors, as shown in

380 ±1

output capacities of 20 kW to 37 kW.

360 ±0.5

600 A amplifier units capable of driving servo motors with

Figure 3, achieving both space and wiring savings. The
power supply unit and amplifier unit both have a height of
380 mm, which is exactly the same as that of the existing
15 kW system for easy installation in the control panel.
3

90

3

90

250 ±1210200 ±1
4-ø9

95 ±1

325

380 ±1

5

35

・
・
・

360 ±0.5

180
135

90

5

10

Mounting hole:6-ø4.0

27.5

5

90
80

Fig. 4 Dimensions (Power supply unit 37 kW)

Fig. 5 Dimensions (Amplifier units 300 and 600 A)
Fig. 3 Dimensions (Single-axis EtherCAT control unit)

図版の文字

123

英語版用

2.2
Basic specifications
Condens
2.2.1 Basic specifications of units
Table 1 shows the specifications common to all units, andTable 2 to 4 show the basic specifications of individual units.

Table 1 Common specifications for 400 VAC multi-axis servo systems

Environment

Standards

Operating/storage
temperature

0 to +55˚C / -20 to +65˚C

Operating/storage
humidity

Below 90% RH (non-condensing)Operating altitude

Below 1,000 m

Vibration/impact

4.9 m/s2 / 19.6 m/s2

UL/cULUL 61800-5-1 / C22.2 No274-13

Low Voltage Directive

EN 61800-5-1

EMC Directive

EN 61800-3, EN 61326-3-1

Functional safety*

ISO 13849-1: PL=e
EN 61508 SIL3, EN 62061 SILCL3KC Mark

KN 61000-6-2, KN 61000-6-4* Models with Safe Torque Off function

31

SANYO DENKI Technical Report No.51 May 2021

Development of the SANMOTION R 400 VAC Input Multi-axis Servo Systems (37 kW, 300/600 A)

Table 2 Basic specifications of control unit
Interface

EtherCATSize

90 (W) × 180 (H) × 21 (D) mm
0.12 kg

Mass

SANMOTION R rotary motors

MotorsCompatible
equipment

Battery-less absolute encoder

Standard

Absolute encoder for incremental systems

Encoders

Battery-backup absolute encoder

Options

Wire-saving incremental encoder
STO (Safe Torque Off)

Safety functions• Touch probe

EtherCAT communication• Homing• Firmware update via FoE (File access over EtherCAT)• Parameter upload/download via FoE

General-purpose I/O

Functions

Mechanical vibration/
resonance suppression
Servo tuning

Input: 7, output: 2• Feedforward (FF) vibration suppression control (2 levels)• Vibration control for track control• Adaptive notch filter• Auto tuning response 40 levels• Servo tuning support function• Virtual motor operation

Start-up,monitoring,
diagnosis• Driver recorder• Encoder/amplifier temperature monitoring• Power consumption monitoring• Encoder communication quality monitoring• Service life diagnosis (Relay and holding brake)

Table 3 Basic specifications of power supply unit
Output capacity
Input voltage

37 kW
Main circuit

380 to 480 VAC +10%, -15%

Control circuit

24 VDC ±15%, 4.6 A(When 5 axes of amplifier units connected)

Size

180 (W) × 380 (H) × 295 (D) mm

Mass

16 kg
Wall-mounted

Mounting

Forced air cooling (ducted cooling)

Cooling system

Table 4 Basic specifications of amplifier unit
Amplifier capacity
Input voltage
Output current

300 A

600 A
457 to 747 VDC

Main circuitControl circuit

24 VDC ±15%, 2.2 A

24 VDC ±15%, 2.6 A

Rated output

66 Arms

89 Arms

MaximumCompatible motors

157 Arms

250 Arms

Up to 30 kW

Up to 37 kW

Size

250 (W) × 380 (H) × 295 (D) mm

Mass

20 kg

Mounting
Cooling system

21 kg
Wall-mounted

Forced air cooling (ducted cooling)

SANYO DENKI Technical Report No.51 May 2021

32

2.2.2 Unit configurations
This system allows multiple amplifier units and control
units to be connected to a single power supply unit.
Table 5 shows the series lineup, and Figure 6 shows
various system combinations.

Table 5 System lineup
Single-axis analog

Control unit

4-axis EtherCATSingle-axis EtherCAT

+
16 kW

Power supply unit

37 kW

+
25 A

50 A

75 A

150 A

300 A

600 A

Up to 2 kW

Up to 3.5 kW

Up to 5.5 kW

Up to 15 kW

Up to 30 kW

Up to 37 kW

Amplifier unit
Compatible motors

Unit Lineup

NEW
LINEUPPower supply
unit
16 kW

Servo motor

37 kW

Amplifier
unit
25 A

50 A

75 A

150 A

300 A

600 A
Analog: Max. 6 axes

EtherCAT: Max. 5 axes

Control
unit
Analog (1 axis)

EtherCAT(Max. 4 axes)

EtherCAT (1 axis)

Fig. 6 System unit configurations

33

SANYO DENKI Technical Report No.51 May 2021

Development of the SANMOTION R 400 VAC Input Multi-axis Servo Systems (37 kW, 300/600 A)

3. Features

3.3 Increased control unit performance

3.1 Expanded lineup

SANMOTION R 3E Model servo amplifier. It has better

We newly developed a control unit designed based on the

By adding the 37 kW system to the lineup, we expanded

servo responsiveness and suppresses machine resonancethe 400 VAC input multi-axis system lineup to supportand vibration better than the previous model, while also

output capacities ranging from 550 W to 37 kW. The 37 kW

improving machinery productivity and processing quality. It

power supply unit can also be combined with the existingalso comes with functions for monitoring the status of power

25 to 150 A open-frame amplifier units, as shown in

consumption and encoder communication quality and for

Figure 7. As a result, the 400 VAC lineup is now available inestimating the remaining life of dynamic braking (DB)comparable output variations to that of our 200 VAC multi-

relays and holding brakes. These rich features contribute toaxis servo amplifier.

the environmental diagnosis and preventive maintenance ofIn addition, the control unit is compatible with both
200 VAC and 400 VAC systems, allowing the 200 VAC
system to be replaced without changing the host controller.
Power unit
37 kW

Amp. unit
600 or 300 A

Amp. unit
150 A

Amp. unit
25 to 75 A

machinery.
* Based on our own research as of February 2021.

4. Key Points of Development
As mentioned above, the size of the new models has been
made much smaller than that of our previous models. The
図版の文字
thermal design of a product is a key for downsizing.
Also,
123

large-capacity servo amplifiers require larger英語版用
electrolytic

Condens
capacitors and other components. These components
英語版用must be secured with silicone rubber to suppress
vibration

Times Ten

Conventionally, it had been difficult to automate thisprocess and often needed to be done manually. We will now
introduce the key points of development and the technique
we used to solve this automation challenge.
EtherCAT single-axis control unit

Fig. 7 System illustration

4.1 Optimal heat-dissipating structure
These servo systems are often used in the injection axis of
injection molding machines.
Injection axes involve a process where melted plastic iscooled and solidified in a mold, which requires the motor

3.2 Downsizing and weight reduction
We used latest power modules in the power supply unit

to perform above its rated torque to apply pressure for over
10 seconds.

and amplifier unit to reduce power loss. They also use a

The repetition of this process significantly changes

high-performance heat sink to optimize heat dissipation.

the temperature of the power module (IGBT) used in

Furthermore, we achieved downsizing by using a high-the amplifier unit, and reduces the life of the component

density component layout.

(thermal cycle life).

We also reduced the number of components to reduce

As a solution to this, we optimized the heat-dissipating

weight by using an integrated copper bar structure for the

structure of the new models to suppress this temperature

unit’s internal wiring.

change. In particular, the thermal cycle life is significantly

As a result, the new 600 A amplifier unit has been madeaffected by the thermal capacity of the power module’s

smaller and lighter, achieving a 61% volume and 60%

copper base and heat sink. Recognizing this, we determinedweight compared to the previous model. This realized thethe optimal base thickness through the analysis of theindustry’s smallest size* as a servo system to be combined

temperature change in power modules by modifying the heatwith a 37 kW motor.

sink base thickness using the thermal analysis simulation

The downsizing and weight reduction help reduce its

shown in Figure 8. As a result, we were able to substantiallyoccupancy in customer equipment, and build more flexible

reduce the size, while also securing sufficient component

layouts and downsize customer equipment.

service life and improving the product reliability.

SANYO DENKI Technical Report No.51 May 202134

(1) A 37 kW power supply unit and 300 and 600 A amplifier
Heat sink (base part)

units were added to the lineup. Together with ourprevious models, we now offer an expanded lineup ofPower module

400 VAC multi-axis servo amplifiers that can drive
550 W to 37 kW output motors.
(2) We ach ieved sig n i f icant dow nsi zi ng and weig ht
reduc t ion by opt i m i z i ng t hei r heat- d i s sipat i ng
structures, adopting layouts with higher component
density, and reducing the number of components.
Therefore, we achieved the industry’s smallest* servo
system that can drive 37 kW motors.
(3) We released a control unit designed based on our

Fig. 8 Heat analysis with heat dissipation fin
thickness varied

4.2 Improved fan cover

SANMOTION 3E Model that can help achieve ahigher servo responsiveness and suppress mechanicalresonance and vibration better than previous products.
(4) The new models come with functions for monitoring

To achieve higher component density, we equipped thet he st at u s of p ower c on su mpt ion a nd enc o der

600 A amplifier unit and 37 kW power supply unit withc om mu n ic at ion qu a l it y a nd for e st i mat i ng t hebuilt-in cooling fans.

remaining life of components, allowing them to be

We also designed a new fan cover made from sheet metal
as a countermeasure against intrusion of foreign objects.

used for environmental diagnosis and preventive
maintenance of machinery.

Compared to conventionally used filter kits, we were able
to improve the airflow vs. static pressure characteristics andWe expect that the new models will help achieve space

reduce noise levels. Moreover, since filter replacement is no

and wiring savings in machinery, while also improving

longer necessary, they can be used for a long time with peace

productivity and processing quality.

of mind.

With the addition of new models, the 400 VAC lineup now
covers motor outputs ranging from 550 W to 30 kW, which

4.3 Increased productivity
and production quality
To improve productivity and quality, we have beendeveloping production techniques using automation
technology and robots.
As an anti-vibration measure, the new models use

is comparable to our 200 VAC multi-axis servo amplifier
lineup, providing customers with an even greater choice of
products for their various machinery needs.
Moving forward, we will continue developing andproposing new products that can improve customers’
equipment and create value for our customers.

silicone rubber to secure their large snap-in aluminumelectrolytic capacitors. Conventionally, the applicationof silicone rubber has been done by workers, resulting ininconsistencies in regard to the application area and amountof silicone rubber. For the new models, we devised a methodthat uses robots to do the application. By automating thisprocess, we successfully reduced the inconsistency for
improved productivity and quality.

5. Conclusion
In this article, we introduced the features and key
development points of our new SANMOTION R Model
400 VAC input multi-axis servo systems.

35

SANYO DENKI Technical Report No.51 May 2021

* Based on our own research as of February 2021.

Development of the SANMOTION R 400 VAC Input Multi-axis Servo Systems (37 kW, 300/600 A)

Author

Masaaki Mizusawa
Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

Mitsuru Takasugi
Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

Hiroto Noguchi
Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

Satoshi Hiramitsu
Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

Noriaki Kasuga
Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

Shuhei Nakazawa
Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

SANYO DENKI Technical Report No.51 May 2021

36

Internal Recognition: Invention Excellence Award
Awarded in May 2020
Title

Department

Name

Motor Controller Mounting Structure

Design Dept. 2, Servo Systems Div.

Yuji Ide,
Takao Oshimori,Hiroaki Koike

Control and Magnetic Bias Suppression
for Grid-connected PV Inverter

Design Dept., Power Systems Div.

Makoto Ishida,
Minoru Yanagisawa

Internal Recognition: Manufacturing Excellence Award
Awarded in May 2020
Title

Department

Name

Mold Structure for Improved Releasability

Engineering Sect. 2, Production Dept.
Production, Cooling System Div.

Yoichi Yamada,
Shinsuke Okubo

Subsect. 2, Process Engineering Sect. 1,
Production Engineering Dept., Servo Systems Div.,

Ikuo Takeshita

Production Engineering and Development Sect.,
Production Engineering Dept., Servo Systems Div.

Hideyuki Ayuzawa

SANYO DENKI Techno Service CO., LTD.

Daiki Kobayashi,
Yoshihiro Kojima

High-Precision Assembly Technique
for the Light-Emitting Moduleof Incremental Encoders

37

SANYO DENKI Technical Report No.51 May 2021

Major Patents■ Patents registered in 2020

Registration Number

Title

Inventor(s)Europe - 02458223

AXIAL-FLOW FAN WITH DOUBLE
IMPELLERS

Honami Osawa, Katsumichi Ishihara,
Toshiyuki Nakamura, Takashi Kaise,
Yoshihiko Aizawa, Seiji Nishimura

Europe - 02173022

BRUSHLESS MOTOR STATOR

Izumi Onozawa, Masashi Miyazawa

Europe - 02355309

ELECTRIC FAN

Naruhiko Kudo, Tomoaki Ikeda,
Haruhisa Maruyama

Europe - 02685625

MOTOR CONTROLLER

Takahisa Toda

Europe - 02814167

FAN MOTOR CONTROL UNIT

Yo Muramatsu, Takahisa Toda,
Kenta Nishimaki

Europe - 02811627

FAN MOTOR, INLINE TYPE FAN MOTOR
AND ASSEMBLY METHOD OF THE SAME

Katsumichi Ishihara, Masashi Nomura,
Tomoko Hayashi

China - ZL201410443400.X

THREE−PHASE ELECTROMAGNETIC
MOTOR

Toshihito Miyashita, Manabu Horiuchi

Korea - 102073801

STATOR, METHODFOR MANUFACTURING STATOR,
AND MOTOR

Toshihito Miyashita, Masashi Suzuki,
Manabu Horiuchi, Masaki Musha

U.S. - 10666108

STATOR, METHODFOR MANUFACTURING STATOR,
AND MOTOR

Toshihito Miyashita, Masashi Suzuki,
Manabu Horiuchi, Masaki Musha

Taiwan - I687028

MOTOR STRUCTURE

Toshihito Miyashita, Manabu Horiuchi

Europe - 02996230

STEPPER MOTOR

Yasushi Yoda, Koji Nakatake, Masaaki Ohashi

Hong Kong - HK1216945

STEPPER MOTOR

Yasushi Yoda, Koji Nakatake, Masaaki Ohashi

Taiwan - I682610

STEPPER MOTOR

Yasushi Yoda, Koji Nakatake, Masaaki Ohashi

China - ZL201510772342.X

MOTOR CONTROL APPARATUS

Yuji Ide, Masahisa Koyama, Shintaro Koichi

Taiwan - I691159

MOTOR CONTROL APPARATUS

Yuji Ide, Masahisa Koyama, Shintaro Koichi

China - ZL201511023274.3

FAN CASING AND FAN APPARATUS

Naoya Inada, Honami Osawa

Taiwan - I712357

FAN CASING AND FAN APPARATUS

Naoya Inada, Honami Osawa

Taiwan - I688325

MOTOR CONTROL DEVICE

Yuji Ide, Takao Oshimori, Hiroaki Koike

China - ZL201610079626.5

MOTOR CONTROL APPARATUS

Yuji Ide, Michio Kitahara, Toshio Hiraide

Taiwan - I703809

MOTOR CONTROL APPARATUS

Yuji Ide, Michio Kitahara, Toshio Hiraide

Taiwan - I696808

MEASUREMENT DEVICE

Katsumichi Ishihara, Takahisa Toda,
Yo Muramatsu

Taiwan - I683196

MOTOR CONTROL APPARATUS

Yuji Ide, Michio Kitahara, Toshio Hiraide

China - ZL201610087797.2

MOTOR CONTROL DEVICE

Yuji Ide, Daigo Kuraishi, Akihiko Takahashi,
Toshio Hiraide

Taiwan - I705657

MOTOR CONTROL DEVICE

Yuji Ide, Daigo Kuraishi, Akihiko Takahashi,
Toshio Hiraide

Taiwan - I703270

IMPELLER AND FAN DEVICE

Jiro Watanabe, Masashi Miyazawa,
Akira Nakayama

U.S. - 10781819

IMPELLER AND FAN DEVICE

Jiro Watanabe, Masashi Miyazawa,
Akira Nakayama

China - ZL201610232262.X

BIDIRECTIONAL AXIAL FAN DEVICE

Satoshi Fujimaki, Toshiya Nishizawa,
Takashi Kawashima

Taiwan - I699484

BIDIRECTIONAL AXIAL FAN DEVICE

Satoshi Fujimaki, Toshiya Nishizawa,
Takashi Kawashima

China - ZL201610329511.7

SENSOR FOR MOTOR

Takayoshi Seki

China - ZL201610649891.2

LINEAR MOTOR

Yasushi Misawa, Hiroyuki Sato,
Akihiko Takahashi, Satoshi Sugita

SANYO DENKI Technical Report No.51 May 2021

38

39

Registration Number

Title

Inventor(s)Korea - 102178178

LINEAR MOTOR

Yasushi Misawa, Hiroyuki Sato,
Akihiko Takahashi, Satoshi Sugita

China - ZL201610649582.5

AXIAL BLOWER AND SERIES-TYPE
AXIAL BLOWER

Toshiyuki Nakamura, Shuji Miyazawa

Europe - 03133292

AXIAL BLOWER AND SERIES-TYPE
AXIAL BLOWER

Toshiyuki Nakamura, Shuji Miyazawa

Taiwan - I702340

AXIAL BLOWER AND SERIES-TYPE
AXIAL BLOWER

Toshiyuki Nakamura, Shuji Miyazawa

Japan - 06745661

MOTOR CONTROL APPARATUS

Yuji Ide, Michio Kitahara, Toshio Hiraide

Japan - 06653542

MOTOR CONTROL APPARATUS

Yuji Ide, Michio Kitahara, Toshio Hiraide

China - ZL201610676324.6

MEASUREMENT DEVICE

Masahiro Koike, Tomoaki Ikeda,
Takahisa Toda, Yo Muramatsu,
Katsumichi Ishihara, Hikaru Urushimoto

China - ZL201611177833.0

MOTOR

Manabu Horiuchi, Toshihito Miyashita

Korea - 102192221

MOTOR

Manabu Horiuchi, Toshihito Miyashita

U.S. - 10848019

MOTOR

Manabu Horiuchi, Mai Shimizu, Jun Kitajima

Japan - 06764670

POWER CONVERTER

Kazuya Nishizawa, Takuya Ozawa

Japan - 06680648

MOTOR CONTROL APPARATUS

Yuji Ide, Toshio Hiraide, Keigo Kikuchi

Japan - 06734752

AUTOMATIC ENCODER DETERMINING
DEVICE

Ryuichi Yanagisawa, Masao Mizuguchi

China - ZL201710785510.8

REVERSIBLE FLOW FAN

Yoshihisa Yamazaki

Europe - 03301305

REVERSIBLE FLOW FAN

Yoshihisa Yamazaki

U.S. - 10662973

REVERSIBLE FLOW FAN

Yoshihisa Yamazaki

Europe - 03301306

BLAST FAN

Yoshihisa Yamazaki, Satoshi Fujimaki,
Takashi Kawashima, Soma Araki

Japan - 06802022

BLAST FAN

Yoshihisa Yamazaki, Satoshi Fujimaki,
Takashi Kawashima, Soma Araki

U.S. - 10837345

BLAST FAN

Yoshihisa Yamazaki, Satoshi Fujimaki,
Takashi Kawashima, Soma Araki

U.S. - 10712041

COOLING FAN AUTOMATIC CONTROLSYSTEM AND COOLING FAN AUTOMATIC Naoki Murakami, Masashi Murakami
CONTROL DEVICE

Japan - 06766024

ORDER MANAGEMENT SYSTEM,ORDER MANAGEMENT APPARATUS
AND ORDER MANAGEMENT PROGRAM

Shigejiro Miyata, Keigo Kikuchi

Japan - 06676133

ARMATURE MOLDED STRUCTURE

Manabu Horiuchi, Hiroki Sagara, Jun Kitajima,
Mai Shimizu, Takashi Matsushita

Japan - 06694500

BOBBIN STRUCTURE OF ARMATURE

Manabu Horiuchi, Hiroki Sagara, Jun Kitajima,
Mai Shimizu, Takashi Matsushita

Japan - 06764921

ARMATURE STRUCTURE
OF THREE-PHASE MOTOR

Manabu Horiuchi, Hiroki Sagara,
Mai Shimizu, Jun Kitajima

Japan - 06643519

MOTOR CONTROL APPARATUS
AND INSULATION RESISTANCE

Yuji Ide, Keigo Kikuchi, Toshio Hiraide,
Masakazu Sakai

SANYO DENKI Technical Report No.51 May 2021

Technical Papers Published Outside the Company
in General Technical Journals
January to December 2020
Title of Paper

Authors

Name of Journal

Issued in

Publisher

Feature: Products and Technology
Development of Member Companies SANYO DENKI CO., LTD.
and the Results of 2020

Denki (Electrical
Appliances)

2020.2The Japan Electrical
Manufacturers’
Association (JEMA)

Specialty Technologies for
Efficiently Producing Servo Systems
Products

Shusaku Magotake,Kazuhiro Makiuchi

Monthly JETI

2020.3

Nippon Syuppan
Seisaku Center Inc.

Development of the SANUPS W73A
Grid-connected Isolated Type

Makoto Ishida,
Hirofumi Nishizawa,
Tetsuya Fujimaki,
Katsutoshi Tanahashi

Monthly JETI

2020.4

Nippon Syuppan
Seisaku Center Inc.

Development of SANMOTION R 3E
Model Servo Amplifiers with Built-in
Positioning Function

Naohiro Ito,
Hiroyuki Kosuge,
Kenichi Fujisawa,
Keisuke Ishizaki,
Naoki Kubo,
Hideaki Nishizawa

Monthly JETI

2020.12

Nippon Syuppan
Seisaku Center Inc.

Technical Papers Published Outside the Company
January to December 2020
Title of Paper

Authors

Name of Journal

Issued in

Publisher

Robust Estimation Method
for Stator Temperature Basedon Voltage Disturbance Observer
Autotuning Resistance for SPMSM

Yuji Ide, Daigo Kuraishi,
Akihiko Takahashi(Joint-author: Nagaoka Universityof Technology)

IEEJ Journalof Industry
Applications

2020.7IEEJSANYO DENKI Technical Report No.51 May 2021

40

Memo

41

SANYO DENKI Technical Report No.51 May 2021

51

May 2021

https://www.sanyodenki.com/

Published in Japan on May 15, 2021 by SANYO DENKI CO., LTD.
Published semi-yearly
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Phone +81 3 5927 1020
Publisher Nobumasa Kodama
Editorial Board Members:
Toshihiko Baba
Editor-in-Chief
Satoru Onodera
Managing Editor
Takashi Kobayashi
Secretariat
Shiho Tsukada
Secretariat
Risa Yoshii
Secretariat
Haruhisa Maruyama
Koji Ono
Hirofumi Nishizawa
Makoto Ishida
Daigo Kuraishi
Takao Oshimori
Hitoshi Yoshiike
Rieko Naruse
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No part of this publication may be reproduced in any manner whatsoever without written
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